KR100637886B1 - Parts supply system problem detection support system and method, and media that can record computer program for method there of - Google Patents

Abstract

In order to produce high quality products inexpensively in a large-scale production system, it is necessary not only to eliminate unnecessary waste from production activities in the own process, but also to eliminate reasonable waste from the component supply system and make it reasonable. However, in the present state, there is no way to know whether there is excessive waste in the parts supply system, and whether it is unreasonable or whether the excessive waste is eliminated and reasonable. The hierarchical display of the product and product family list displays at least one kind of part supply information selected from a part manufacturing process, a part score, lead time, and a cost, and the retrieved part supply information is displayed to be distinguishable from other places. The search method can be set arbitrarily. The whole parts supply system is intentionally marked to make the problem material clear.

Description

PARTS SUPPLY SYSTEM PROBLEM DETECTION SUPPORT SYSTEM AND METHOD, AND MEDIA THAT CAN RECORD COMPUTER PROGRAM FOR METHOD THERE OF}

The present invention is a production system in which a high-level parts are produced in the next step using the parts produced in the previous process, and a chain in which a higher-level part is produced in a continuous step is repeated in a multi-step using the high-dimensional parts produced in the next step. The present invention relates to a technology that enables the production of high quality products at low cost in a short time.

For example, an automobile produces a coil in the previous process, an armature is produced using the coil in the next process, and a motor is produced using the armature in the next process, and then the motor is used in the next process. The fuel pump is produced, the fuel pump assembly is produced using the fuel pump in the next process, and the fuel tank subassembly is produced using the fuel pump assembly in the next process, and the fuel tank subassembly is then processed in the next process. Car is produced. In a typical production system, high-dimensional parts are produced in the next step by using parts produced in the previous process, and chains to produce higher-dimensional parts in a continuous process are repeated in multiple steps by using high-dimensional parts produced in the next step. have.

In this specification, the numbering from the side which produces a high-dimensional component is made, and the process of producing a final product is called a magnetic process. In the above example, the coil is produced in the sixth process, the armature is produced in the fifth process, the motor is produced in the fourth process, the fuel pump is produced in the third process, and the second process. In the fuel pump assembly is produced, the fuel tank subassembly is produced in the first process, the fuel tank subassembly produced in the first process is fed to the magnetic process, and produces a product called automobile in the magnetic process.

In addition, the said 1st process is a magnetic process which produces the product of a fuel tank subassembly. When it considers as a 1st process, the said 2nd process is a 1st process, and a 3rd process The secondary process can be said to be a secondary process. All the processes using the parts are called magnetic processes, and the processes preceding the components can be called primary processes, secondary processes, tertiary processes and the like. The technique of the present invention is a technique for realizing the potential problem in a part supply chain for supplying parts to a magnetic process, and is applicable to all processes produced using parts.

In order to be able to produce high-quality products at low cost in a short time in a production system consisting of a chain of parts supply, it is not only reasonable to eliminate excessive waste from the production activities of the self-process, but also eliminates unnecessary waste in the component supply system. Er need to be reasonable. For example, in each process of the parts supply system, it is required that the incidence of defective products during parts production is low, the number of parts in stock is low, the parts are produced and delivered in a short delivery time, and the parts ordered parts are compressed and concentrated.

However, in the present state, there is no way to know whether there is excessive waste in the parts supply system and whether it is unreasonable or whether excessive waste is eliminated and reasonable. Japanese Patent Laid-Open No. 2001-331535 and Japanese Patent Laid-Open No. 9-267239 provide a list of the first parts group to be delivered to the magnetic process, a list of the second parts group constituting each first part, and each of the second parts. Disclosed is a technique of schematically illustrating parts development information indicating a relationship between a third part group list to be constituted. According to this, the parts development table displayed by the hierarchical tree structure or the object model is displayed, and when a high-dimensional part is designated, the low-dimensional part group list which comprises the high-dimensional part is known.

Even if the low-dimensional parts group list constituting the high-dimensional parts is displayed schematically, it is not possible to know whether it is unreasonable and unreasonable in the parts supply system or whether it is reasonable because the unreasonable waste is eliminated. .

The present invention is to create a technique to present the problems (unreasonable waste) present in the supply system of parts supplied through various processes. This technology not only makes the above problems present, but also measures can be taken to solve them, making it possible to produce high quality products at low cost in a short time. In the process of taking measures, the ability of the superior parts production process to produce high-quality parts inexpensively and in short periods of time is now available, which makes it possible to legitimately evaluate competent production processes.

The present invention has created a system that makes it easy to find a problem by presenting a problem of a parts supply system.

In this system, high-level parts are produced in the next step using the parts produced in the previous process, and higher-level parts are produced in the continuous process by using the high-dimensional parts produced in the next step. It is used in the product production system that produces the product in its own process by using the final part (primary part) produced in the production process (primary process).

The product here is not limited to the product seen by the consumer. As illustrated above, the fuel tank subassembly is also a product in the process of producing the fuel tank subassembly, and the fuel pump assembly is the primary component for the magnetic process of producing the fuel tank subassembly as a product. As schematically shown in FIG. 1, a motor is produced in a fourth process, a fuel pump is produced in a third process, a fuel pump assembly is produced in a second process, and a fuel tank is produced in a first process. When the subassembly is produced and the automobile is produced in its own process, the second process is the first process, and the third process is the main process, considering the process of producing the product called the fuel tank subassembly. It can be said to be a secondary process. Since all processes produced using parts can be self-processing, the system can be applied to all product usage processes.

The system finds potential problems in the parts supply system by presenting potential problems in the parts supply system (primary process and upstream process group) of the final parts (primary parts) supplied to the magnetic process. Support.

The system of this invention is equipped with each of the following means.

(1) Part development information which stores the product and the adjacent low-dimensional parts list which comprises the product, the chain of the low-dimensional parts, and the lower level parts list which comprises it in multiple steps, and the part development For each low-level part included in the information, the parts production process, the score of the parts necessary for the production of the high-dimensional parts, the properties of the parts, the number of parts, the logistics information of the parts, the moving distance of the parts, Means for storing at least one kind of part supply information selected from a defective rate, a cost of a part, and a lead time of a part.

1 illustrates a case where the product produced in the magnetic process is A. The first part group list is displayed on the right side of the product A, the second part group list is displayed on the right side of the first part, and the third part group list is displayed on the right side of the second part. On the right side of the tertiary part, a fourth part group list is displayed. In FIG. 1, the first component B1 is required to produce the product A, the second component groups C1 and C2 are required to produce the first component B1, and the second component C1 is required. The third parts group (D1, D2) is required to produce this, and the fourth parts group (E1, E2, E3, E4) is needed to produce the third part (D1).

(2) A means for graphically displaying the part development relationship stored in the storage means and the part supply information stored in correspondence with each part.

(3) A means for searching the parts supply information stored in correspondence with the parts according to a predetermined search condition.

(4) means for displaying the parts retrieved by the retrieval means and / or the parts supply information stored in correspondence with the parts so as to be distinguishable from other places in the schematic display.

For example, in the example shown typically in FIG. 1, the component supply information b1 of the primary component B1 is displayed in correspondence with the primary component B1. In addition, the secondary components C1 and C2 are displayed on the schematic display in which the primary component B1 is developed, and the product supply information c1 of the secondary component C1 is corresponding to the secondary component C1. ) Is displayed, and the component supply information c2 of the secondary component C2 is displayed corresponding to the secondary component C2. The component supply information b1, c1, c2 is one kind of information on the component supply of the components B1, C1, C2. Specifically, the part production process (some may exist) and the production of high-dimensional components. The number of parts required, the attributes of the parts (e.g., whether they are dedicated parts or general purpose parts), the number of types of parts, the logistics information of the parts (for example, whether they are delivered after they have been stocked in a warehouse, or Whether it is paid directly from the production process, whether it is delivered via a supervisor or directly), the moving distance of the part, the defective rate at the time of producing the part, the cost of the part, or the lead time of the part. The selected information is one kind or two or more kinds.

The search conditions can be set in various ways, and parts produced in a predetermined number of production processes, parts requiring a predetermined number or more, parts having a predetermined number or more, parts corresponding to a predetermined logistics condition, parts exceeding a predetermined moving distance It is possible to search for a part exceeding a predetermined amount of bubbles, a part having a predetermined cost or more, a part requiring a predetermined lead time or more, and the like. The search condition may be set in advance or may be set as necessary.

As schematically shown in Fig. 1, when the parts development relationship and the parts supply information stored in correspondence with each part are schematically displayed, the whole of the parts supply system can be grasped through the time.

Here, if the parts searched in accordance with a predetermined search condition and / or the parts supply information stored in correspondence with the parts are displayed to be distinguishable from other places in the schematic display, there is a problem that exists in the parts supply system (eg For example, the presence of parts having a large number of adjacent low-dimensional parts scores, the presence of parts with long lead times, the presence of very expensive parts, and the like are presently supported to effectively detect the problem.

The information amount schematically shown in FIG. 1 is enormous and cannot be maintained easily. In the self process, for the primary parts produced in the first process, it is easy to examine the production process, the number of parts, the attributes and types of parts, the logistics conditions, the moving distance, the defective rate, the cost, and the lead time. In the second and third stages of the process, a great deal of investigation is required.

Therefore, a plurality of storage means includes a means for storing part development information which stores a chain of parts and a low-level parts group list constituting the parts in multiple stages and parts supply information for each part included in the part development information. It is desirable to configure it by connecting to a network.

In this case, each storage means is provided in each production step, and stores part development information indicating a part produced in the part production step and a low-dimensional part group list constituting the part. In addition, parts supply information is stored in association with low-level parts. In addition, each memory means stores the link information for the memory means which is provided in the production process which is equipped with the memory means and supplies a low-dimensional component to a production process.

In the case of Fig. 1, the second component of the first component B1 is stored in the storage means of the first process as C1, C2, and the second component C1 is stored in the storage means of the second process. The third component is stored as D1 and D2, and the fourth component of the third component D1 is stored as E1, E2, E3, and E4 in the storage means of the third process. In addition, the storage means 103 of the first process stores link information to the storage means 105 of the second process that stores the second component C1 as a production part, and the storage means of the second process. In 105, the link information to the storage means 107 of the third process, in which the third component D1 is stored as a production part, is stored.

By connecting a plurality of storage means via a network, a component development information storing a chain of parts and an adjacent low-dimensional parts group list constituting them in multiple stages, and means for storing parts supply information of each component In each production process, only the information which is comparatively easy to investigate is maintained, and the database which describes the whole parts supply system of the large-scale production system which becomes a large amount of information is maintained in a short time.

Although the search conditions can be set in various ways, it is preferable to search using the reference value as the search condition. It is also preferable that a means for displaying a list of standard countermeasures for achieving the reference value is added to the item searched for not satisfying the reference value.

For example, when the scores of the low-dimensional parts constituting the part are stored, the parts requiring a plurality of low-dimensional parts can be extracted by searching for the parts requiring a predetermined number or more of the low-dimensional parts. In this case, when standard measures for reducing the number of necessary parts, for example, the integration of parts or the inventory of the design, are displayed, the presence of the problem and the countermeasure thereof are displayed, and the problem of the parts supply system is rapidly improved. It is expected to be.

It is preferable that the production process is correspondingly displayed for each of the low-dimensional parts of the schematic part development information.

In this case, the fact that parts supply processes for producing the same parts are duplicated and parts supply processes with a lot of parts supply problems are obvious, and necessary measures are easily taken. Alternatively, an excellent component supply process is apparent, and on the component supply process side, an opportunity of appropriately evaluating his or her ability is obtained, and it is easy to find an excellent component supply process on the process side that receives the component supply. Alternatively, it is easy to establish an excellent component supply path. In other words, it is easy to establish a parts supply system that supplies parts at low cost in a short time.

It is preferable that the scores required to produce the high-dimensional parts for each of the low-dimensional parts of the schematic part development information are displayed correspondingly.

In this case, it is possible to specify a part requiring a plurality of low-dimensional parts, so that it is easy to find a part that requires integration, integration or assembly of the low-dimensional parts.

It is preferable that attributes are displayed corresponding to each component of the schematic part development information.

The attribute of a part here means whether it is a dedicated part used only for one type of product, a common part commonly used for several types of products, or a general-purpose part circulated to the public in the market.

The common use and general purpose of the parts can reduce the cost and lead time, and the phenomenon from this viewpoint can be easily grasped.

It is preferable that the number of types of parts is displayed corresponding to each component of the schematic part development information.

In this case, it is possible to identify a component in which many kinds exist, and it is possible to examine the design and easily find a component that requires a common or series of components.

 It is preferable that the logistics information from the production process of the component to the next process is correspondingly displayed corresponding to each component in the schematic of the component development information.

The logistics information referred to here refers to information indicating, for example, whether the product is to be stored in stock at the warehouse and then delivered or delivered via a supervisor. Logistics costs may be included if necessary.

If the logistics information is displayed, the unnecessary waste of payment terms is visualized and the problem is present.

It is preferable that the moving distance from the production process of the component to the next process is displayed corresponding to each component of the schematic part development information.

If the travel distance required for parts delivery is indicated, the problem of the geographic location of the parts production process is visualized and currentized.

It is preferable that the defective rate at the time of manufacturing parts is displayed corresponding to each part of the schematic part development information.

If the probability of defective products is indicated at the time of production, the production process that is causing problems in the production activity is present, and the production process can be urged for quality improvement measures.

It is preferable to display the cost of the part corresponding to each part of the schematic part development information.

In this case, parts important for cost reduction are apparent, and information necessary for factor analysis with high cost is also displayed, and effective measures are easily taken for cost reduction.

It is preferable that the lead time is displayed corresponding to each part of the schematic part development information.

In this case, parts important for shortening the lead time are obvious, and information necessary for the analysis of the cause of the long lead time is also displayed, so that effective measures are easily taken to shorten the lead time.

It is more preferable that the lead time of each part is divided and displayed by the lead time from ordering to delivery.

For example, if the lead time is displayed for each period required from the time of ordering to the start of production, the period from the start of production until the end of production, the stock period from the end of production to the shipment, and the transportation period from shipment to delivery, the lead time is shortened. Effective measures are easy to take. In addition, the detail display of lead time is not limited to the above-mentioned example.

It is more preferable that the lead time of each part is displayed as the total lead time which accumulated the lead time from the lowest dimension part which comprises the part to the adjacent low dimension part.

For example, if the lead time of the fourth part is 0.5 days, the lead time of the third part is 0.5 days, and the lead time of the second part is 0.5 days, the total lead time of the first part is 1.5 days. The total lead time is displayed at a glance.

At least one selected from the scores of parts, the attributes of parts and the number of types of parts required for the production of high-dimensional parts corresponding to the low-level parts of the schematic of component development information, the cost of parts, and the lead time of parts It is preferable to be displayed as possible.

In this case, technical information, cost information, and lead time information on the parts composition are displayed in a ready-to-use manner, so that it is possible to comprehensively grasp the parts supply system from the technical, production and logistical aspects. This is easy to take.

In addition to the above items, other necessary items may also be displayed.

The present invention has created a method of making the problem easy to find by presenting the problem of the parts supply system. In the method of the present invention, each process is performed.

(1) In each parts production process, the list of adjacent low-dimensional parts groups required for the production of the parts is maintained in correspondence with the parts produced in the production process, and the parts At least one part supply information selected from the production process, the number of parts required, the properties of the parts, the number of parts, the logistics information of the parts, the moving distance of the parts, the defective rate of the parts production, the cost of the parts, the lead time of the parts Process to maintain database by maintenance.

(2) A step of maintaining link information to a database maintained in each production step, and to a database storing adjacent low-dimensional parts as production parts in the database.

(3) A step of graphically displaying the development relationship of the group of parts constituting the product using the link information and the parts supply information stored in correspondence with each part.

In this method, a list of adjacent low-dimensional parts groups required for the production of the parts is maintained in correspondence with the parts produced in each part production process. In addition, at least one component supply information is maintained corresponding to each adjacent low-dimensional component. At this time, it is sufficient to irradiate adjacent low-dimensional component production processes and component groups, and there is no need to investigate retrospectively, so that a reliable database can be completed relatively easily.

In order to maintain the information maintained in each production process and the information linking to the database storing the parts supply information of the low-dimensional parts, a group of independently maintained databases constitutes a large database with one mass. .

In the case of FIG. 1, it is described that the secondary components constituting the primary component B1 are C1 and C2 in the database 103 of the first process, and the second is stored in the database 105 of the second process. It is remembered that the third components constituting the secondary component C1 are D1 and D2, and the fourth components constituting the third component D1 in the database 107 of the third process are E1, E2, In addition to being stored as E3 and E4, the link information to the database 105 of the secondary process which stores the secondary component C1 as a production part is stored in the database 103 of the primary process, In the database 105 of the secondary process, link information to the database 107 of the tertiary process in which the tertiary part D1 is stored as a production part is stored.

The following program is useful for constructing a large-scale database having one chunk by using link information of the above database, that is, a plurality of independent databases. The program of the present invention executes the following steps by controlling a computer managed by each production process.

(1) urging to input a list of adjacent low-dimensional parts groups required for the production of the parts in correspondence with the parts produced in the production process;

(2) Parts production process, required parts scores, parts properties, number of parts, logistics information, distance of parts, defect rate in parts production, cost of parts in correspondence with each low-level parts Prompting the input of at least one kind of component supply information selected from the lead time of the component.

(3) A step of prompting input of link information to a database in which a production process for which adjacent low-dimensional parts delivered to the production process is a production part is maintained.

Using this program in each part production process, a database is built to complete the database describing the entire large-scale parts supply system that is chained in multiple stages by simply inputting data on adjacent low-level parts groups. The database does not necessarily have to be completed without gaps, and functions even if some data is not obtained.

The method of the present invention may be said to be a method of presenting the advantages and disadvantages of the parts supply system until the parts are supplied to the production process. In this method, each of the following steps is carried out.

(1) In the process of part production,

(1a) maintain a list of adjacent low-level parts groups necessary for the production of parts produced in the middle of the process;

(1b) maintain at least one of the scores, attributes, and number of types of adjacent low-dimensional parts needed;

(1c) maintain at least one of the lead time and cost of adjacent low-level components needed;

The process of creating a database of the process,

(2) The process of producing the link information about the database which the process of producing the adjacent low-dimensional components which the intermediate process requires goes through the above-mentioned procedure.

Here, the format of each database is common. It is characterized by the above-mentioned.

The production process of parts is various, and mainly various processes such as a process using chemical reaction, a process centering on machining, a process centering on assembly, and a process centering on heat treatment. Neither process is striving to remove waste from its own process. Naturally, numerical information about the productivity of the process is collected and analyzed. At this time, since the nature of the process varies, each process is quantified for each situation. In chemical process-oriented processes, productivity is evaluated in units of lots that react at one time. However, in the case of analyzing the whole part supply system, this is the cause and the data cannot be comprehensive.

According to the present invention, it was confirmed that even in various processes, even when hierarchical parts development were given, costs, lead times, and the like could be developed in parts, and a common format could be used. It was also confirmed that a database describing the entire parts supply system was obtained by using a common format.

By this method, a database describing the entire parts supply system which has not been available so far is obtained, and by interpreting it, the advantages and disadvantages existing in the parts supply system are brought to the present.

The present invention is well understood by reading the description of the embodiments with reference to the drawings described below.

1 is a schematic diagram of a hierarchical tree structure of parts stored in part development information;

2A is a diagram showing an example of a system configuration of a problem detection support system of a component supply system;

Fig. 2B is a diagram showing an example of a system configuration of a problem detection support system of a parts supply system;

2C is a diagram showing an example of a system configuration of a problem discovery support system of a component supply system;

3 is a flowchart showing a procedure of creating and using a parts supply system database;

Fig. 4 is a diagram showing an example in which the parts supply system database displays the related items, reference values, and countermeasure lists on the user interface.

FIG. 5 is a diagram showing an example of hierarchical tree structure of parts development information stored in a parts supply system database, and iconized for each part and displayed on a user interface; FIG.

6 is a diagram showing an example in which parts supply information, reference values, and standard countermeasure lists are displayed for each part in the parts supply system database;

7 is a diagram showing an example in which supply information of parts is schematically displayed at the location of the location of the production process on the map;

Fig. 8 is a diagram showing the display of results obtained by taking standard countermeasures or the like for not meeting the standard values of the parts supply information.

Next, an example of embodiment of this invention is demonstrated. 2A, 2B, and 2C show the system configuration of the problem detection system of the component supply system according to an example of the embodiment of the present invention.

As shown in Figs. 2A, 2B, and 2C, a computer 203 for analyzing a problem of a parts supply system in a network 201, a magnetic process computer 207, a computer 230 installed in a first production process, The computer 240 installed in the secondary production process is connected. The illustrated computer is a part, and a plurality of primary production processes exist, and a plurality of primary production processes computers also exist. There are also a plurality of secondary production processes, and a plurality of secondary production processes computers. In addition, a computer of a lower-level production process than the third production process is also connected to the network 201. Input and output devices are connected to each computer.

As shown in Fig. 2A, the problem analysis computer 203 of the component supply system includes a search program for searching the component supply information stored in correspondence with each component of the component development information, a reference value and a standard for achieving the reference value. A database storing a list of countermeasures and a database storing the location and name of the production process are stored. In addition, a program for creating and outputting a component supply system data table (to be described later) is stored.

As shown in Fig. 2A, the magnetic process computer 207 stores a component supply system database creation program and a component supply system database. The parts supply system database stores parts development information that stores the relationship between the product and the parts group (primary parts group) constituting the product, and data corresponding to parts supply information for each of the first parts group. .

As shown in FIG. 2B and FIG. 2C, the computers 230 and 240 installed in the production process include the parts produced in the production process in which the computer is installed, the adjacent low-dimensional parts group constituting them, and the low Parts supply information for each dimension part is input and stored.

As shown in FIG. 2A, FIG. 2B, and FIG. 2C, the magnetic process computer 207, the production process computers 230, 240, etc. link through the network 201, and comprise the large-scale database in which one mass exists. Doing.

Fig. 3 shows the processing procedure from the construction of the database describing the parts supply system to the current problem.

As shown in S301 of FIG. 3, one database is maintained using the magnetic process computer 207, the production process computers 230 and 240, and the component supply system database creation program.

Specifically, as shown in FIGS. 2A, 2B, and 2C, 207, 230, and 240, a component (produced in the case of the magnetic process) produced in the magnetic process and a component group of adjacent low-dimensional components constituting it List and supply the parts supply information of adjacent low-dimensional parts. By using the program, this information is maintained in a formal standard format.

An example of the database created in FIG. 2A, FIG. 2B, FIG. 2C is shown. The database is composed of a magnetic process computer 207, production process computers 230, 240, and the like.

As shown in Fig. 2A, the product area 209 of the database of the magnetic process computer 207 displays the product produced in the magnetic process. Although the name "A" is indicated here, it may be displayed by an article number or the like. In addition, below the 1st process, the parts produced by each process are represented as a product.

In the component part area 211, adjacent low-dimensional parts groups constituting the product of the product area 209 are displayed. In FIG. 1, "B1" and "B2" are shown as components constituting the product "A". The primary computer 230 stores that the primary component "B1" is produced using the secondary components "C1" and "C2", and the secondary computer 240 stores the secondary component "C1". It is remembered that it is produced using the car parts "D1" and "D2".

In the component part production process area 213, a mark indicating a production process for producing adjacent low-dimensional parts is made. In Fig. 2A, the location and name of the part production process are shown. Specifically, the component "B1" is produced in "Okazaki 2Aa" and "Okazaki 3Bb" which mean "process a of line A of plant 2 in Okazaki" and "process b of line B of plant 3 in Okazaki." It is illustrated.

In the component score area 215, the component scores are displayed numerically. Here, the part score refers to the total number of adjacent low dimensional parts used to manufacture one product (parts produced in each step in the first step and below).                 

The component type number and component attribute area 217 display the component type number and attributes. Here, as the number of types of components, which version is manufactured for the same component is indicated by numbers. In addition, as an attribute of a component, it is displayed separately whether it is a dedicated product, a common product, or a general purpose product. In FIG. 1, there are two versions of the component "B1" produced by "Okazaki 2Aa", and the numeral "2" is indicated as the component type. In addition, since "B1" is an exclusive article, it is displayed in the "exclusive article" column of a component attribute.

The logistics information area 219 stores logistics information from a part production process to a delivery process. When goods delivered from stock are delivered, they are marked “stock”; when they are delivered via a supervisor, “the boss”; when they are paid on condition that payment is required for payment services, “payment cost” is indicated.

In the movement distance area 221, the movement distance from the production process of each component to the next process is indicated by the horizontal bar axis corresponding to the length. For example, the distance from the "process a of the line A of the plant 2 in Okazaki" which is a production process corresponding to a 1st component (B1) to the magnetic process is memorize | stored.

In the defective rate area 223, the probability of defective products occurring during the production of parts is indicated by the bar axis in the horizontal direction corresponding to the percentage (%).

In the cost area 225, the cost of the parts is indicated by the bar axis in the horizontal direction corresponding to the height of the price.

In the lead time area 227, the lead time from ordering of parts to delivery is indicated by the bar axis in the horizontal direction corresponding to the length of time. Here, the lead time is displayed by dividing the lead time from each order to the delivery stage, and the production lead time required for the completion of production after receiving the order in the low-dimensional production process and stored until the finished parts are shipped. It is represented by any one of the stock lead time, the delivery lead time which shows the time taken for conveyance between the low dimensional production process, and the high dimensional production process, or a sum thereof. In Fig. 2A, each of production lead time, stock lead time, and transport lead time and their totals are displayed.

The database of the same structure is created also in the production process computer 230 of FIG. 2B, and the database of the same structure is also produced of the production process computer 240 of FIG. 2C. In this case, in the magnetic process computer 207 of FIG. 2A, a component that is a primary component is stored as a product in the computer 230 of the first process of FIG. 2B, and the computer 230 of the first process is used. In FIG. 2C, the component, which is called the primary component, is stored as a product in the computer 240 of the secondary process of FIG. 2C.

The database maintained separately for each computer 207, 230, and 240 is linked in order from the high-dimensional process to the low-dimensional process as needed by utilizing link information to the low-dimensional process. Specifically, as shown in 229 of FIG. 2A, 233 of FIG. 2B, and 241 of FIG. 2C, a computer of a production process for producing adjacent low-dimensional parts is a link paper. 2A, 2B, and 2C, the computer 230 installed in the production process of Okazaki 2Aa in the data of Okazaki 2Aa of the primary component B1 of the computer 207 of the magnetic process by the link information 229. The data installed in the Hamamatsu 1Ba, which produces the parts C1, is linked to the data of the product B1, and the data of the Hamamatsu 1Ba of the part C1 of the computer 230 installed in the production process of the Okazaki 2Aa is linked by the link information 233 ( The data of product C1 of 240 is linked.

In the case of FIGS. 2A, 2B, and 2C, a database relating to a system for supplying parts constituting product A is mixed in a column of product A of a database maintained in a magnetic process in which A is produced, and linked to the column. It illustrates that. The database regarding the supply system of the components constituting the primary component B1 is exemplified by being mixed in the column of the product B1 of the database maintained in Okazaki 2Aa where B1 is produced and linked to the column. Similarly, the database concerning the supply system of the parts constituting the second part C1 required for the first part B1 is mixed in the column of the product C1 of the database maintained in Hamamatsu 1Ba where C1 is produced. The example illustrates linking to a column.

The linked data is edited into large-scale data with one lump accumulated from a low dimension in the analysis computer 203 of the component supply system, and the component supply system database is formed by chaining component groups and storing them in multiple stages. It is completed (FIG. 3, S301).

Thus, in each production process, the database which describes the whole parts supply system of the large-scale production system which becomes a huge amount of information only by maintaining the next adjacent information which is comparatively easy to investigate is created.

The component supply system database edited and completed by the component supply system analysis computer 203 is displayed by the output device of the component supply system analysis computer 203 or the magnetic process computer 207 (FIG. 3, S303). .

For the edited parts supply system database, a retrieval process is executed in the analysis computer 203 of the parts supply system. 3 shows the flow of the display order. First, for each item of the part distribution information, a target reference value and standard countermeasures in the case of not meeting the reference value are determined and made into a list, and a database is made on the analysis computer 203 of the parts supply system (S305). Next, a part that does not meet the reference value is searched for (S307). From the search results, the names and / or parts supply information of the parts that do not meet the reference values are highlighted so that they can be seen and recognized once by the output device 205 of the analysis computer 203 of the parts supply system. A list of standard countermeasures is also displayed. In this way, it is expected that the problem of the component supply system will be rapidly improved by displaying the problems of the components and the countermeasures thereof.

4 shows an example in which a reference value and standard countermeasures are displayed in a parts supply system database created using link information. In this case, the component parts are displayed in a multi-level tree structure. Specifically, the column of the uppermost part "B1" reaches to the left end of the component part area, and it is shown that the part "B1" is the adjacent low-dimensional part of the product "A". In addition, it is shown that "B1" is produced in two production processes of "Okazaki 2Aa" and "Okazaki 3Bb." The column of "C1" located at the lower end of "B1" starts near the right side more than the column of "B1", and it is displayed that "C1" is an adjacent low-dimensional component of "B1", and "C1" It is shown that these two production processes are being produced. Similarly, the column of "D1" starts near the right side more than the column of "C1", and it shows that "D1" is an adjacent low-dimensional component of "C1" and is produced by two production processes.

In the reference value 401, a numerical value of a specific reference value or the like appears during ejection, and the numerical value may also be specified by a straight line in the longitudinal axis direction or the like. For example, as shown in 401, the number of parts is a reference value. In addition, "200" becomes a reference value about the moving distance, and is indicated by the straight line of a vertical axis.

In addition, the standard countermeasure 403 is displayed for each part about the item which does not satisfy a reference value. For example, in the column of the component part production process, the same part is produced at two places, and while the number of overlaps is "2", the reference value is "1" and it shows that "densification" which is a standard measure in that case is necessary. In this case, the symbol "A" represents "densification." Similarly, "4" pieces exceeding the reference value "2" are used for the parts score, and it is indicated that "integration" (symbol B) which is a standard measure in that case is required. Since the number of parts and parts properties are set as "exclusive parts 2" which exceeds the standard value "common parts 1", it is displayed that "standardization or generalization (symbol C)" which is a standard measure in that case is required. Similarly, for each item that does not meet the criteria, the standard measures for meeting the criteria are indicated. If the criteria are not met for the logistics information, "Direct delivery (D)" is displayed, "Shortening (E)" is displayed for the travel distance, and "Quality improvement (F)" is displayed for the defective rate. For the cost, "Reduce the number of parts and generalize the parts (G)" is displayed, and for the lead time, "Reduce the shortening distance (H)" etc. are displayed. In addition, the illustrated standard measures are a part, and a plurality of standard measures may be written together.

If the parts supply system is well maintained, the standard values are met for most parts, and the non-standard values are clearly shown in the schematic display.

As shown in S311 and S313 of FIG. 3, the display method which combined the reference value and the standard countermeasure with the schematic display of the component supply system data can be changed in various ways.

5 and 6 show examples in which the parts and the supply information of the parts are schematically displayed in a hierarchical tree shape as a display example of S313 in FIG. 3.

In Fig. 5, the parts development information stored in the parts supply system database is hierarchically structured, iconized for each part, and displayed on the user interface. Although the part 501 is not displayed on the actual user interface, it is a convenient description to help understand the correspondence between each part and its production process. For example, when the icon 503 of the component B1 is clicked, the component supply information, the reference value, and the standard countermeasure of the component B1 are displayed as a list.

An example in which the list is displayed is shown in FIG. 6. Box 601 shows the semantic content displayed in box 603. As shown in the box 601, the lead time from the production process to the adjacent high-dimensional process is shown below the arrow on the left side of the box. In the case of the box 603, the number of days is indicated by the number "0.5" under the arrow. In addition, the part name is shown in the "constituent part name" column in the box 601, and is labeled "B1" in the box 603. Similarly, in the column of "Production process location name" of the box 603, "Okazaki 2Aa" which means the process a of the line A of the factory 2 in Okazaki as the location and name of the process which produces the component B1. It is marked. In the column of the "part score" of the box 603, the number "4" which shows that a high-dimensional component is produced using four component parts B1 is displayed. In the column of the number of parts types of the box 603, a part named B1 is a dedicated product, and is marked as "exclusive two types" which means that two types exist. In the column of "Logistics Information", "Stock" is indicated, which means that the parts B1 are shipped from the stock and delivered. In the column of "travel distance", "50 km" indicating the distance from the production process of Okazaki 2Aa to the adjacent high-dimensional process is indicated. In the next column of "defective rate", it is indicated that the probability of defective products occurring at the time of manufacture of the component B1 is "11%". The lowest cost column indicates that the value of the component B1 is 1050 yen. In addition, "cumulative L / T" accumulates the lead time from the lowest low dimensional process to the adjacent low dimensional process, and is marked with "10 days" in the box 603.

What is highlighted in the box number in the box 603 does not satisfy the reference value. In the box 603, the standard countermeasures (indicated by the symbol of the alphabet) for each supply information are displayed corresponding to the countermeasure column in the box 601.

In this way, the information is collectively displayed for each part to clarify which items exist for the part.

As an example of display in S313 of FIG. 3, an example in which the supply information of parts is schematically displayed at the position of the location of the production process on the map is shown in FIG. 7.

For example, a production process in which Okazaki 2Aa, which produces part B1 for product A, is called a first step, and Hamamatsu 1Ba, which produces part C1, is a second step, and part D1 is delivered to Hamamatsu 1Ba. It is assumed that the third process is referred to as the fourth process, and the production process in which the component E1 is delivered to the third process is referred to as a fourth process. In this case, on the map, the magnetic process for producing product A is indicated by the indication "0" (meaning the magnetic process) at the location of the location (701). Similarly, with the indication that Okazaki 2Aa is "1" (meaning the first process) at the location of the location (703), Hamamatsu 1Ba means "2" at the location of the location (the second process). ) 705, and the production process for supplying part D1 to Hamamatsu 1Ba is indicated as "3" (meaning that it is a third process) at the location of the location 707, and the part E1 is The production process delivered to the 3rd process is displayed 711 by the indication "4" (it shows a 4th process) at the position of the raw material. In addition, a straight line is connected between the adjacent high dimensional production process and the adjacent low dimensional production process.

By these displays, the linear distance between the position of the location of each production process and the adjacent high dimensional production process shown by each straight line, and the adjacent low dimensional production process becomes visually clear.

Here, when the moving distance between the adjacent high dimensional production process and the adjacent low dimensional production process is longer than a reference value, the straight line of the part can be highlighted. For example, in FIG. 7, the straight line distance between the third process 707 and the fourth process 711 is highlighted by a thick line (709). If you click on the display of each process indicated by 701, 703, 705, 707, and 711, the supply information about the parts produced in each process, whether or not the standard is met, and the standard measures when not satisfied are displayed in detail. . For example, when the part 703 of "1" is clicked on, detailed display shown by 713 is carried out.

In addition, as an example of display of S313 of FIG. 3, FIG. 8 shows an example of the display of the result of taking standard measures etc. for not meeting the standard value of each component supply information.

The schematic representation of the hierarchical tree in 801 of FIG. 8 is already shown in FIG. 5 and shows a part of the components constituting the product A. FIG. The new parts supply system obtained as a result of taking standard measures against each component (B1, C1, D1, D2, E1, E2, E3, E4) displayed here is hierarchical tree shape within 802. It is indicated by the schematic of. As a result of taking standard measures, it can be seen that the parts D2, E2, and E3 are deleted. In addition, as parts are removed, the low-dimensional process is reduced to the third process.

Here, what countermeasures were taken. For example, since D2 does not meet the standard value in the parts properties area, a list of standard countermeasures "C" has appeared, meaning "commonization". As a result of the commonization of the parts, D2 was deleted because D2 became a common product with D1 and integrated into D1. In addition, since E2 and E3 were found to be produced in a different line in the same factory as the production process of E1 from the component production process, E2 and E3 were assembled into E1 in advance in the factory to form one component. E3 has been deleted. In this way, the number of parts is reduced, or the number of chains in the processes from the magnetic process to the lowest dimension is reduced, so that the product cost and the lead time can be shortened.

By comparing the display 801 before taking the standard countermeasure with the display 802 after taking the standard countermeasure, it can be seen that the number of products reported decreases once, so that the effect of taking the countermeasure clearly can be understood. Can be.

Also, for each part in 802 of FIG. 8, parts supply information, reference values, and standard measures as indicated by the box 603 of FIG. 6 are displayed as a list by clicking on the icon of each part. By clicking the icon of the same part in the list and comparing it with the list, it is possible to know how each supply information is optimized.

In addition, the parts supply system database can perform a search process by setting search conditions in various ways. When a search condition is input in S315 of FIG. 3, a search process is performed (S317), and a search result is displayed (S319). By performing the searching process in this way, for example, when the search condition is a reference value, the parts and related items which do not meet the reference value can be easily identified, and the problem becomes immediately apparent.

According to the present invention, it is possible to grasp all the production processes and parts such as which low-dimensional parts and which low-dimensional processes have problems in the production process of the product, and what countermeasures can be taken against the problems. Can be. As a result of each measure, an efficient production and supply system can be achieved by producing a high-quality product in a short time and inexpensively while minimizing the inventory of the low-dimensional parts held in the high-dimensional production process.

The embodiment described above is merely an example of the present invention, and the technical scope of the present invention is not limited to the examples. Those skilled in the art can implement the present invention in various forms among the technical ideas described in the claims.

Claims (18)

High-level parts are produced in the next process by using the parts produced in the previous process, and the high-level parts produced in the next process are supplied to the next process, and the chain in which higher-dimensional parts are produced in the next process is multi-step. In a system that supports the discovery of a problem by repeating and indicating a potential problem in the parts supply system from the final part production process to producing the final part and supplying it to the product production process, The product and the closest low-level parts list (the first parts list) constituting it, and the low-level parts and the lower-level parts list (the second parts constituting the first part) The moving distance of the parts with respect to the parts development information storing the chain of the group list, the 3rd parts group list constituting the secondary parts, etc. in multiple stages, and the low-dimensional parts included in the parts development information. A "part development information / part supply information" storage means correspondingly storing at least one kind of part supply information selected from a defective rate during part production, a part cost, and a part lead time; Reference value storage means for storing reference values of each parts supply information; And a means for graphically displaying the part development relationship stored in the above-mentioned "part development information / part supply information" storage means and parts supply information stored in correspondence with each part, In the part development information, the information of the supply source is associated and stored for the low-dimensional parts, and the part development information is stored for each part production process. In the schematic display means, the parts supply system is shown graphically, the parts and parts supply information are displayed in the diagrammatic parts supply system, and the parts supply information includes a status display for knowing whether or not the reference value is satisfied. Problem detection support system of the component supply system, characterized in that. High-level parts are produced in the next process by using the parts produced in the previous process, and the high-level parts produced in the next process are supplied to the next process, and the chain in which higher-dimensional parts are produced in the next process is multi-step. In a system that supports the discovery of a problem by repeating and indicating a potential problem in the parts supply system from the final part production process to producing the final part and supplying it to the product production process, The product and the closest low-level parts list (the first parts list) constituting it, and the low-level parts and the lower-level parts list (the second parts constituting the first part) The moving distance of the parts with respect to the parts development information storing the chain of the group list, the 3rd parts group list constituting the secondary parts, etc. in multiple stages, and the low-dimensional parts included in the parts development information. A "part development information / part supply information" storage means correspondingly storing at least one kind of part supply information selected from a defective rate during part production, a part cost, and a part lead time; Means for retrieving parts supply information stored in correspondence with parts according to a predetermined search condition; And a means for graphically displaying the part development relationship stored in the above-mentioned "part development information / part supply information" storage means and parts supply information stored in correspondence with each part, In the part development information, the information of the supply source is associated and stored for the low-dimensional parts, and the part development information is stored for each part production process. In the schematic display means, the parts supply system is shown graphically, the parts and parts supply information are displayed in the displayed parts supply system, and the parts and / or parts supply information corresponding to the parts supply information retrieved by the search means. A problem detection support system of a component supply system, characterized in that the display is displayed so as to be distinguished from the component supply information that is not retrieved from the search means. The method of claim 2, Means for storing a reference value of each component supply information is added, And said retrieval means is provided with a means for retrieving the reference value as a retrieval condition, and for displaying the list of standard measures for achieving the reference value with respect to the component supply information retrieved as not satisfying the reference value. Problem detection support system. The method according to claim 1 or 2, The means for storing the part development information for each part production step stores the part as a production part among the storage means provided in the production step for supplying the low-level parts constituting the parts produced in the production step. Problem finding support system for a component supply system, characterized in that for storing the link information for the data. The method according to claim 1 or 2, A problem detection support system for a component supply system, characterized in that a production process is displayed correspondingly to each of the low-level components developed in the component development information. The method according to claim 1 or 2, A problem discovery support system for a component supply system, characterized in that parts development information corresponding to the logistics information from the production process to the next process of each component is displayed. The method according to claim 1 or 2, The total lead time accumulated from the lowest low-level parts constituting each component to the closest low-level parts is displayed, and the disassembly lead time divided by stages is displayed. Support system. The method according to claim 1 or 2, The component development information includes a score required for the production of the high-dimensional components, at least one selected from the attributes of the components, the number of types of components, the cost of the components, and the lead time of the components. Problem detection support system of supply system. High-level parts are produced in the next process using the parts produced in the previous process, and the chain in which higher-level parts are produced in the next process using the high-dimensional parts produced in the next process is repeated in multiple stages, and the final parts In a method of supporting the discovery of a problem by indicating a potential problem in the parts supply system from producing the final part in the production process to supply to the product production process, A database that maintains a list of the closest low-level parts groups required for the production of parts in correspondence with the parts produced in the production process in each part production process, and a database maintained by the production process that produces each closest low-level part. It maintains the link information for and maintains at least one part supply information selected from the moving distance of the parts, the defective rate in the parts production, the cost of the parts, and the lead time of the parts in correspondence with each of the closest low-level parts. Maintenance process, A process of setting a reference value of each component supply information; A process of graphically displaying a development relationship of a group of parts constituting a product using the link information, a supply system of parts constituting a product, and parts supply information stored in correspondence with each part, In the schematic display step, the component supply information includes a status display for knowing whether or not the reference value is satisfied. High-level parts are produced in the next process using the parts produced in the previous process, and the chain in which higher-level parts are produced in the next process using the high-dimensional parts produced in the next process is repeated in multiple stages, and the final parts In a method of supporting the discovery of a problem by indicating a potential problem in the parts supply system from producing the final part in the production process to supply to the product production process, A database that maintains a list of the closest low-level parts groups required for the production of parts in correspondence with the parts produced in the production process in each part production process, and a database maintained by the production process that produces each closest low-level part. It maintains the link information for and maintains at least one part supply information selected from the moving distance of the parts, the defective rate in the parts production, the cost of the parts, and the lead time of the parts in correspondence with each of the closest low-level parts. Maintenance process, Searching the parts supply information stored in correspondence with the parts according to a predetermined search condition; A process of graphically displaying a development relationship of a group of parts constituting a product using the link information, a supply system of parts constituting a product, and parts supply information stored in correspondence with each part, And in the schematic display step, the parts and / or parts supply information corresponding to the retrieved parts supply information are displayed so as to be distinguishable from the parts supply information not found. High-level parts are produced in the next process using the parts produced in the previous process, and the chain in which higher-level parts are produced in the next process using the high-dimensional parts produced in the next process is repeated in multiple stages, and the final parts In a computer-readable recording medium that stores a program to assist in the discovery of a problem by indicating a potential problem in the parts supply system from the production process to the production of the final part to supply to the production process, In the computer, each of the following steps, namely It is a database maintained by each parts production process, and the list of the closest low-level parts group necessary for the production of the parts corresponding to the parts produced by the production process, and the production process that produces each of the closest low-dimensional parts Link information on the database to be maintained and at least one part supply information selected from the moving distance of the parts corresponding to each of the closest low-dimensional parts, the defective rate at the time of production, the cost of the parts, and the lead time of the parts are maintained. Obtaining information from a database; Setting a reference value of each component supply information; Utilizing the link information to perform a step of graphically displaying the development relationship of the group of parts constituting the product, the supply system of the parts constituting the product, and the parts supply information stored corresponding to each part, In the schematic display step, the component supply information includes a status display for knowing whether or not the reference value is satisfied. Record carrier. High-level parts are produced in the next process using the parts produced in the previous process, and the chain in which higher-level parts are produced in the next process using the high-dimensional parts produced in the next process is repeated in multiple stages, and the final parts In a computer-readable recording medium that stores a program to assist in the discovery of a problem by indicating a potential problem in the parts supply system from the production process to the production of the final part to supply to the production process, In the computer, each of the following steps, namely It is a database maintained by each parts production process, and the list of the closest low-level parts group necessary for the production of the parts corresponding to the parts produced by the production process, and the production process that produces each of the closest low-dimensional parts Link information on the database to be maintained and at least one part supply information selected from the moving distance of the parts corresponding to each of the closest low-dimensional parts, the defective rate at the time of production, the cost of the parts, and the lead time of the parts are maintained. Obtaining information from a database; Retrieving the parts supply information stored in correspondence with the parts according to a predetermined search condition; Utilizing the link information to perform a step of graphically displaying the development relationship of the group of parts constituting the product, the supply system of the parts constituting the product, and the parts supply information stored corresponding to each part, In the schematic display step, a program for finding a problem in a parts supply system, characterized by displaying the parts and / or parts supply information corresponding to the retrieved parts supply information so as to be distinguishable from the parts search information not found. Recordable computer-readable recording medium. delete delete delete delete delete delete

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